Process for producing olefin compounds utilizing a regenerative heat exchanger

Abstract

A method for producing olefin compounds may include contacting a feed stream comprising one or more hydrocarbons with a particulate solids catalyst in a reactor. Within the reactor, the one or more hydrocarbons may be dehydrogenated to form one or more products comprising one or more olefin compounds, and at least a portion of the particulate solids catalyst may be deactivated. The method may also include sending at least a portion of the deactivated particulate solids catalyst to a combustor. Within the combustor, an auxiliary fuel stream may enter the combustor through an auxiliary fuel distributor, and the auxiliary fuel stream may react to heat at least a portion of the deactivated particulate solids catalyst. The method may also include passing at least a portion of the heated deactivated particulate solids catalyst through an oxygen treatment zone to produce a reactivated particulate solids catalyst. The method may also include returning at least a portion of the reactivated particulate solids catalyst to the combustor. Within the combustor, the reactivated particulate solids catalyst may enter the combustor downstream of the auxiliary fuel stream relative to a flow direction of the auxiliary fuel steam, and the deactivated particulate solids catalyst may enter the combustor upstream of the auxiliary fuel stream relative to a flow direction of the auxiliary fuel stream. The method may also include passing at least a portion of the reactivated particulate solids catalyst through a reactor.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 428,528, filed November 29, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] FIELD OF THE INVENTION FIELD OF THE INVENTION Embodiments described herein relate generally to chemical processing, and more particularly to processes and systems utilized for the production of olefinic compounds. [Background technology]

[0003] Olefin compounds can be used as base materials to produce many types of goods and materials. For example, propylene can be used to produce polypropylene, propylene oxide, and acrylonitrile. Such products can be used in product packaging, chemical manufacturing, fibers, etc. Therefore, there is an industry demand for olefin compounds such as ethylene, propylene, butene, and styrene, as well as processes for producing such materials. Summary of the Invention

[0004] One method of producing olefinic compounds is by dehydrogenating hydrocarbons. In some embodiments, the dehydrogenation reaction can use a particulate solid, such as a catalyst, to promote the dehydrogenation reaction. Furthermore, due to the endothermic nature of the dehydrogenation reaction, the reaction may also utilize an external heat source to promote the reaction. In such embodiments, the particulate solid can be delivered to a combustor, where an auxiliary fuel reacts to heat the particulate solid. The heated particulate solid can provide some or all of the heat utilized to continue the dehydrogenation reaction. However, reacting the auxiliary fuel in the presence of the particulate solid can reduce the activity of the particulate solid in promoting the dehydrogenation reaction. Therefore, it is desirable to limit the amount of particulate solid exposed to the auxiliary fuel while providing a sufficient heat source for the dehydrogenation reaction. The method of the present disclosure can help limit the amount of particulate solid exposed to the auxiliary fuel by delivering both deactivated and reactivated particulate solids into the combustor in a specific distribution pattern. Specifically, the embodiments described herein utilize a method in which a deactivated particulate solids catalyst is routed into the combustor upstream of the supplemental fuel and a reactivated particulate solids catalyst is routed into the combustor downstream of the supplemental fuel. Such an arrangement can be beneficial by extending the residence time of the deactivated catalyst in the combustor, allowing for more complete combustion of coke, while the regenerated catalyst recycled to the combustor generally contains less coke and can benefit from a reduced residence time exposed to the supplemental fuel, which can deactivate the catalyst.

[0005] According to one or more embodiments of the present disclosure, a method for producing olefin compounds may include contacting a feed stream comprising one or more hydrocarbons with a particulate solids catalyst in a reactor. Within the reactor, the one or more hydrocarbons may be dehydrogenated to form one or more products comprising one or more olefin compounds, and at least a portion of the particulate solids catalyst may be deactivated. The method may also include sending at least a portion of the deactivated particulate solids catalyst to a combustor. Within the combustor, an auxiliary fuel stream may enter the combustor through an auxiliary fuel distributor, and the auxiliary fuel stream may react to heat at least a portion of the deactivated particulate solids catalyst. The method may also include passing at least a portion of the heated deactivated particulate solids catalyst through an oxygen treatment zone to produce a reactivated particulate solids catalyst. The method may also include returning at least a portion of the reactivated particulate solids catalyst to the combustor. Within the combustor, the reactivated particulate solids catalyst may enter the combustor downstream of the auxiliary fuel stream relative to a flow direction of the auxiliary fuel steam, and the deactivated particulate solids catalyst may enter the combustor upstream of the auxiliary fuel stream relative to a flow direction of the auxiliary fuel stream. The method may also include passing at least a portion of the reactivated particulate solids catalyst through a reactor.

[0006] It should be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and features of the claimed subject matter. Additional features and advantages of the embodiments are set forth in the detailed description, and in part will become readily apparent to those skilled in the art from that description, including the accompanying drawings and claims, or can be learned by practicing the described embodiments. The drawings are included to provide a further understanding of the embodiments and, together with the detailed description, serve to explain the principles and operation of the claimed subject matter. However, the embodiments shown in the drawings are illustrative and exemplary in nature and are not intended to limit the claimed subject matter. [Brief explanation of the drawings]

[0007] The following detailed description can be better understood when read in conjunction with the following drawings. [Figure 1] FIG. 1 is a schematic diagram illustrating a reactor system according to one or more embodiments of the present disclosure. [Figure 2] 1 and 2 are schematic illustrations of a combustor according to one or more embodiments of the present disclosure. In illustrating the simplified schematics of Figures 1 and 2, many valves, temperature sensors, electronic controllers, etc., which are available and known to those skilled in the art, are not included. Additionally, accompanying components often included within such reactor systems, such as air supplies, heat exchangers, surge tanks, etc., are also not included. However, it should be understood that these components are within the scope of the present disclosure.

[0008] Reference will now be made in more detail to various embodiments, some of which are illustrated in the accompanying drawings. DETAILED DESCRIPTION OF THE INVENTION

[0009] Specific embodiments of the present application will now be described. However, this disclosure may be embodied in different forms and should not be construed as limited to the embodiments set forth in this disclosure. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present subject matter to those skilled in the art.

[0010] As described herein, a method for producing olefin compounds may include reactivating a catalyst in a combustor by exposure to a supplemental fuel. In embodiments described herein, the deactivated particulate solids catalyst and the recycled reactivated particulate solids catalyst may be fed separately to the combustor in different regions of the combustor. As described herein, "particulate solids catalyst" refers to a particulate solid that may have catalytic functionality for dehydrogenation reactions and / or fuel combustion reactions. When the term "particulate solids" is used herein, it may equally refer to a "particulate solids catalyst."

[0011] Embodiments of the methods disclosed herein are described in detail herein with reference to the reactor system of FIG. 1 and the combustor of FIG. 2 operating as a circulating fluidized bed for dehydrogenating hydrocarbons. However, it should be understood that the principles disclosed and taught herein may be applicable to other systems utilizing different system components oriented in a different manner. For example, the concepts described herein may be equally applicable to other systems with alternative reactor and regeneration units, such as those operating under non-fluidized conditions or those including a downer rather than a riser, and vice versa. Furthermore, it should be understood that not all parts of the reactor system of FIG. 1 and the combustor of FIG. 2 should be construed as essential to the claimed subject matter. Furthermore, although the method steps recited in the appended claims are described herein in the context of the reactor system of FIG. 1 and the combustor of FIG. 2, it should be understood that such recited method steps are adaptable to other systems, as would be understood by one of ordinary skill in the art.

[0012] Referring now to FIG. 1 , an exemplary reactor system 103 that may be suitable for use in the methods and / or apparatuses described herein is schematically illustrated. The reactor system 103 generally comprises multiple system components, such as a reactor section 206 and a regeneration unit 306. As described herein, a “system component” refers to a portion of the reactor system 103, such as, for example, a reactor, a separator, a transfer line, or a combination thereof. As used herein in the context of FIG. 1 , the reactor section 206 generally refers to the portion of the reactor system 103 where the primary process reaction (e.g., dehydrogenation) occurs to form a product stream. A feed stream enters the reactor section 206, is converted to a product stream (containing product and unreacted feed), and exits the reactor section 206. The reactor section 206 comprises a reactor 202, which may include an upstream reactor section 254 and a downstream reactor section 232. 1 , reactor section 206 may further include a particulate solids separation section 216 that serves to separate the particulate solids catalyst from the chemical products formed in reactor 202. Also, as used herein, regeneration unit 306 generally refers to a portion of reactor system 103 that processes the particulate solids in some manner, such as by combustion, to improve catalyst activity and / or heat the particulate solids. Regeneration unit 306 may include combustor 350 and riser 330, and may further include particulate solids separation section 316. In one or more embodiments, particulate solids separation section 216 may be in fluid communication with combustor 350 (e.g., via line 426), and particulate solids separation section 316 may be in fluid communication with upstream reactor section 254 (e.g., via line 424 and transfer riser 430).

[0013] Generally, as described herein, in the embodiment illustrated in FIG. 1 , a portion of the particulate solids is circulated between the reactor section 206 and the regeneration unit 306. It should be understood that references to particulate solids herein may refer to solid materials that are catalytically active for a desired reaction (i.e., catalysts) or may equally refer to other particulate solids mentioned with respect to the system of FIG. 1 that do not necessarily have catalytic activity but affect the reaction, such as oxygen carrier materials. The terms “catalytic activity” refer to the extent to which a catalyst is capable of catalyzing a reaction taking place in the reactor system 103. The particulate solids exiting the reactor section 206 may be deactivated particulate solids. As used herein, “deactivated” may refer to particulate solids that are less catalytically active or at a lower temperature compared to the particulate solids entering the reactor section 206. However, deactivated particulate solids may retain some catalytic activity. The reduced catalytic activity may result from contamination with materials such as coke. Reactivation (sometimes referred to herein as "regeneration") may remove contaminants such as coke, increase the temperature of the particulate solid, or both. In embodiments, a deactivated particulate solid may be reactivated by reactivating the particulate solid in regeneration unit 306. The deactivated particulate solid may be reactivated by, but is not limited to, removing coke by combustion, restoring catalyst acidity, oxidizing the particulate solid, heating the particulate solid, other reactivation processes, or combinations thereof. In one or more embodiments, the particulate solid may be heated during reactivation by combustion of an auxiliary fuel, such as hydrogen, methane, ethane, propane, natural gas, or combinations thereof. Without being bound by theory, it is believed that if the particulate solid is heated during reactivation by combustion of an auxiliary fuel, exposure of the particulate solid to the fuel gas may deactivate the particulate solid while also heating the particulate solid.As used herein, the term "heated deactivated particulate solids catalyst" refers to particulate solids catalyst that has been heated by combustion of auxiliary fuel, but may still have reduced catalytic activity. The reactivated particulate solids from the regeneration unit 306 may then be returned to the reactor section 206.

[0014] A feed stream may enter reactor 202 through feed inlet 434, and a product stream may exit reactor system 103 via pipe 420. According to one or more embodiments, reactor system 103 may be operated by supplying a chemical feed (e.g., in a feed stream) and particulate solids to upstream reactor section 254. The chemical feed contacts the particulate solids in upstream reactor section 254, and each flows upward into and through downstream reactor section 232 to produce chemical products.

[0015] Referring now in detail to FIG. 1 , the reactor section 206 may include an upstream reactor section 254, a transition section 258, and a downstream reactor section 232, such as a riser. The transition section 258 may connect the upstream reactor section 254 with the downstream reactor section 232. As shown in FIG. 1 , the upstream reactor section 254 may be positioned below the downstream reactor section 232. Such a configuration may be referred to as an upflow configuration for the reactor 202. The upstream reactor section 254 may comprise a vessel, drum, barrel, vat, or other suitable containment vessel for a given chemical reaction. As shown in FIG. 1 , the upstream reactor section 254 may be connected to the downstream reactor section 232 via the transition section 258. The upstream reactor section 254 may generally comprise a larger cross-sectional area than the downstream reactor section 232. The transition section 258 may taper from the cross-sectional size of the upstream reactor section 254 to the cross-sectional size of the downstream reactor section 232 such that the transition section 258 projects inward from the upstream reactor section 254 toward the downstream reactor section 232. For example, the transition section 258 may be a frustum.

[0016] The upstream reactor section 254 may be connected to a transfer riser 430 that can provide regenerated particulate solids in the feed stream to the reactor section 206 during operation. The particulate solids entering the upstream reactor section 254 via the transfer riser 430 may be routed through line 424 to the transfer riser 430, arriving from the regeneration unit 306. The particulate solids may enter the transfer riser 430 directly from the particulate solids separation section 216 via a water column 422, where they enter the upstream reactor section 254. This particulate solids may be somewhat deactivated, but may still be suitable for reaction in the upstream reactor section 254 in some embodiments, especially when used in conjunction with regenerated / reactivated particulate solids.

[0017] 1 , in one or more embodiments, based on the shape, size, and other process conditions (such as temperature and pressure) of the upstream reactor section 254 and the downstream reactor section 232, the upstream reactor section 254 can operate as a fluidized bed, such as a fast fluidized bed, turbulent bed, or bubbling bed upflow reactor, while the downstream reactor section 232 can operate more in a plug flow regime, such as a riser reactor. For example, the reactor 202 of FIG. 1 may include the upstream reactor section 254 operating as a fast fluidized bed, turbulent bed, or bubbling bed reactor and the downstream reactor section 232 operating as a dilute-phase riser reactor, such that the average particulate solids and gas flows move upward simultaneously. "Average flow," as that term is used herein, refers to net flow, i.e., total upward flow minus countercurrent or reflux flow, as is generally typical of fluidized particle behavior. As used herein, a "fast fluidization" reactor may refer to a reactor that utilizes a fluidization regime in which the superficial velocity of the gas phase is greater than the choking velocity and that may be semi-dense during operation. As used herein, a "turbulent" reactor may refer to a fluidization regime in which the superficial velocity is less than the choking velocity and that is denser than the fast fluidization regime. As used herein, a "bubble bed" reactor may refer to a fluidization regime in which well-defined bubbles within a dense bed exist in two distinct phases. "Choking velocity" refers to the minimum velocity required to maintain solids in a dilute phase mode in a vertical conveying line. As used herein, a "dilute phase riser" may refer to a riser reactor that operates at a transport velocity, in which the gas and particulate solids have approximately the same velocity in the dilute phase.

[0018] In one or more embodiments, the particulate solid may be capable of fluidization. In some embodiments, the particulate solid may exhibit what is known in the industry as "Geldart A" or "Geldart B" properties. Particles may be classified as "Group A" or "Group B" according to D. Geldart, Gas Fluidization Technology, John Wiley & Sons (New York, 1986), 34-37, and D. Geldart, "Types of Gas Fluidization," Powder Technol. 7 (1973) 285-292, which are incorporated herein by reference in their entireties.

[0019] Group A is understood by those skilled in the art to represent aerated powders with bubble-free fluidization; high bed expansion; slow, linear degassing rate; bubble characteristics where splitting / re-coalescing bubbles may predominate, with maximum bubble size and large wake; high levels of solids mixing and gas backmixing assuming equal U-Umf (where U is the carrier gas velocity and Umf is the minimum fluidization velocity, typically but not necessarily measured in meters per second, m / s, i.e., excess gas velocity exists); axisymmetric slug characteristics; and no eruptions except in very shallow beds. Assuming equal cfp, the listed properties tend to improve as the average particle size decreases; or as the fraction less than 45 micrometers (μm) increases; or as the gas pressure, temperature, viscosity, and density increase. Generally, particles with small average particle size and / or low particle density (1.4 grams per cubic centimeter, g / cm) 3 They exhibit a viscosity of less than 1000 psi, are easily fluidized with smooth fluidization at low gas velocities, and may exhibit controlled foaming with small bubbles at higher gas velocities.

[0020] Group B begins to foam at Umf; exhibits moderate bed expansion; rapid degassing; has no limitation on bubble size; assuming U-Umf is equal, the levels of solid mixing and gas backmixing are moderate; both axisymmetric and asymmetric slags; and jets only in shallow beds; is understood by those skilled in the art as representing a "sand-like" powder. These characteristics tend to improve as the average particle size decreases, but the particle size distribution, and with some uncertainty, the gas pressure, temperature, viscosity, or density do not appear to contribute much to the improvement of the above characteristics. Generally, most of the particles have a particle size (cfp) of 40μm < cfp < 500μm when the density (ρp) is 1.4 < pp < 4 g / cm 3 in the case of 4 g / cm 3 in the case of 60μm < cfp < 500μm, and a density (ρp) of 1 g / cm 3 in the case of 250μm < cfp < 100μm.

[0021] According to an embodiment, the chemical product and the particulate solid may be discharged from the downstream reactor section 232 and sent to the separator 226 within the solid separation section 216, where the particulate solid is separated from the chemical product and the chemical product is transferred out of the particulate solid separation section 216. According to one or more embodiments, following separation from the water vapor in the separator 226, the particulate solid may generally move through the stripping zone 224 to the particulate solid outlet port 222, where the particulate solid is transferred out of the reactor section 206 via line 426 and enters the regeneration unit 306.

[0022] Referring back to FIG. 1 , according to one or more embodiments, separator 226 may be a cyclonic separation system that may include two or more stages of cyclonic separation. In embodiments in which separator 226 includes two or more stages of cyclonic separation, the first separator into which the fluidized stream enters is referred to as the primary cyclonic separator. The fluidized effluent from the primary cyclonic separator may enter a secondary cyclonic separator for further separation. Primary cyclonic separators may include, for example, primary cyclones and systems commercially available under the names VSS (commercially available from UOP), LD2 (commercially available from Stone and Webster), and RS2 (commercially available from Stone and Webster). Primary cyclones are described, for example, in U.S. Pat. Nos. 4,579,716, 5,190,650, and 5,275,641, each of which is incorporated herein by reference in its entirety. In some separation systems utilizing a primary cyclone as the primary cyclone separator, one or more sets of additional cyclones, e.g., secondary and tertiary cyclones, are used to further separate particulate solids from the product gas. It should be understood that any primary cyclone separator may be used in embodiments of the present invention.

[0023] Continuing with reference to FIG. 1 , the separated particulate solids are sent from the particulate solids separation section 216 via line 426 to the combustor 350. In the combustor 350, the particulate solids may be processed, for example, by combustion with one or both of oxygen and an auxiliary fuel. For example, without limitation, the particulate solids may be decoked and / or fuel may be combusted to heat the particulate solids. The particulate solids then exit the combustor 350 through the riser 330 to the end-of-riser separator 378, where the gas and solid components from the riser 330 are at least partially separated. The water vapor and remaining solids are transferred to the secondary separator 326 within the particulate solids separation section 316, where the remaining particulate solids are separated from gases from the particulate solids processing (e.g., gases emitted by the combustion of spent particulate solids or fuel, referred to herein as flue gas). The flue gas may exit the regeneration unit 306 via an outlet pipe 432. The separated particulate solids are then sent via line 424 and transfer riser 430 through oxygen treatment zone 312 in particulate solids separation section 316 to upstream reactor section 254 where they are further utilized in catalytic reactions. In one or more embodiments, at least a portion of the particulate solids are sent from oxygen treatment zone 312 to combustor 350. Thus, the particulate solids may be circulated between reactor section 206 and regeneration unit 306 during operation. Generally, the treated chemical streams, including the feed stream and the product stream, may be gaseous, and the particulate solids may be fluidized particulate solids.

[0024] Referring now to the regeneration unit 306, as shown in FIG. 1 , the combustor 350 of the regeneration unit 306 may be in fluid communication with the riser 330. An oxygen-containing gas, such as air, may be delivered into the combustor 350 through a pipe 358. The combustor 350 may be in fluid communication with the particulate solids separation section 216 via a line 426, which may supply deactivated particulate solids from the reactor section 206 to the regeneration unit 306 for regeneration. The combustor 350 may also be in fluid communication with the oxygen treatment zone 312, which may supply reactivated particulate solids to the reactor section 206 and the combustor 350. The combustor 350 and the riser 330 may operate in a fluidization regime similar to or identical to that disclosed for the upstream reactor section 254 and the downstream reactor section 232 of the reactor section 206. That is, the combustor 350 may operate as a fluidized bed, such as in a fast fluidized bed, turbulent bed, or bubbling bed upflow reactor, while the riser 330 may operate in a plug flow regime, such as in a riser reactor. The geometries described with respect to the upstream reactor section 254 and the downstream reactor section 232 are equally applicable to the combustor 350 and the riser 330. Additionally, the combustor 350 may also include an auxiliary fuel distributor 354 that may supply fuel, such as a hydrocarbon stream, hydrogen, or a combination thereof, to the combustor 350.

[0025] The particulate solids and flue gas produced in the combustor 350 may travel through a riser 330 to a particulate solids separation section 316. In the particulate solids separation section 316, the flue gas and particulate solids may be separated first by an end-of-riser separator 378 and then by a secondary separator 326. As described in one or more embodiments, following separation of the flue gas from the particulate solids in the end-of-riser separator 378 and secondary separator 326, treatment of the treated particulate solids with an oxygen-containing gas occurs in an oxygen treatment zone 312. In some embodiments, the oxygen treatment zone 312 comprises a fluid-solid contactor. The fluid-solid contactor may include baffles or grid structures to facilitate contact of the treated catalyst with the oxygen-containing gas. Examples of fluid-solid contactors are described in more detail in U.S. Pat. Nos. 9,827,543 and 9,815,040. The fluidization regime in the oxygen treatment zone may be a bubbling bed fluidization.

[0026] In one or more embodiments, the particulate solids may be exposed to the oxygen-containing gas in the oxygen treatment zone 312 for between 30 seconds and 20 minutes. For example, the particulate solids may be exposed to the oxygen-containing gas in the oxygen treatment zone 312 for between 30 seconds and 18 minutes, e.g., between 30 seconds and 16 minutes, between 30 seconds and 14 minutes, between 30 seconds and 12 minutes, between 30 seconds and 10 minutes, between 30 seconds and 8 minutes, between 30 seconds and 6 minutes, between 30 seconds and 4 minutes, between 30 seconds and 2 minutes, between 2 minutes and 20 minutes, between 2 minutes and 18 minutes, between 2 minutes and 16 minutes, between 2 minutes and 14 minutes, between 2 minutes and 12 minutes, between 2 minutes and 10 minutes, between 2 minutes and 8 minutes, between 2 minutes and 6 minutes, between 2 minutes and 4 minutes, between 4 minutes and 20 minutes, between 4 minutes and 18 minutes, between 4 minutes and 16 minutes, between 4 minutes and 14 minutes, between 4 minutes and 12 minutes, between 4 minutes and 10 minutes, between 4 minutes and 8 minutes, between 4 minutes and 6 minutes, between 6 minutes and 20 minutes, between 6 minutes and 1 minute. The oxygen-containing gas may be exposed for 8 minutes, 6 to 16 minutes, 6 to 14 minutes, 6 to 12 minutes, 6 to 10 minutes, 6 to 8 minutes, 8 to 20 minutes, 8 to 18 minutes, 8 to 16 minutes, 8 to 14 minutes, 8 to 12 minutes, 8 to 10 minutes, 10 to 20 minutes, 10 to 18 minutes, 10 to 16 minutes, 10 to 14 minutes, 10 to 12 minutes, 12 to 20 minutes, 12 to 18 minutes, 12 to 16 minutes, 12 to 14 minutes, 14 to 20 minutes, 14 to 18 minutes, 14 to 16 minutes, 16 to 20 minutes, 16 to 18 minutes, or 18 to 20 minutes.

[0027] In one or more embodiments, a portion of the particulate solids may pass through oxygen treatment zone 312 and be returned to reactor section 206 via line 424. In one or more embodiments, a portion of the particulate solids may pass through oxygen treatment zone 312 and be returned to combustor 350 via line 356 and pipe 428. Pipe 428 may separately carry a portion of the particulate solids coming from oxygen treatment zone 312 via line 356 and a portion of the particulate solids coming from particulate solids separation section 216 via line 426 to particulate solids distributor 100, which may be operable to route the two particulate solids portions separately into combustor 350.

[0028] In one or more embodiments, at least a portion of the particulate solids may be removed from the oxygen-treatment zone 312 after passing through only a portion of the oxygen-treatment zone. For example, even if the oxygen-treatment zone 312 exposes the particulate solids to the oxygen-containing gas for five minutes, a portion of the particulate solids may be removed from the oxygen-treatment zone after only one minute of exposure to the oxygen-containing gas. In one or more embodiments, a portion of the particulate solids removed from the oxygen-treatment zone 312 without passing through the entire oxygen-treatment zone 312 may be sent to the combustor 350 as reactivated particulate solids (not shown in FIG. 1 ).

[0029] Referring now to FIG. 2, an exemplary combustor 350 that may be suitable for use with the methods described herein is illustrated schematically. FIG. 2 illustrates the combustor 350 used as a fluidized fuel gas combustor system for a dehydrogenation process. However, the methods described herein may be used with a variety of combustor systems, as will be understood by those skilled in the art. The combustor 350 may include a generally cylindrical lower portion 351 and an upper portion including a frustum 353. The angle between the frustum 353 and an internal horizontal imaginary line drawn at the intersection of the frustum 353 and the lower portion 351 may range from 10 to 80 degrees. All individual values ​​and subranges between 10 and 80 degrees are included and disclosed herein. For example, the angle between the tubular component and the frustum 353 component may range from a lower limit of 10, 40, or 60 degrees to an upper limit of 30, 50, 70, or 80 degrees. For example, the angle may be between 10 and 80 degrees, or alternatively between 30 and 60 degrees, or alternatively between 10 and 50 degrees, or alternatively between 40 and 80 degrees. Further, in alternative embodiments, the angle may vary continuously or discontinuously along the height of frustum 353. In some embodiments, combustor 350 may or may not be lined with a refractory material.

[0030] In one or more embodiments, an auxiliary fuel stream can enter the combustor 350 through an auxiliary fuel distributor 354. In one or more embodiments, the auxiliary fuel stream can include hydrogen, methane, ethane, propane, natural gas, or combinations thereof. In the combustor 350, the auxiliary fuel can react with oxygen and / or the particulate solids. Without being bound by theory, it is believed that combustion of the auxiliary fuel in the combustor 350 can heat the particulate solids. However, it is also believed that contacting the particulate solids with the auxiliary fuel stream can reduce the dehydrogenation activity of the particulate solids. Aside from the combustion of the auxiliary fuel, coke from the particulate solids can also be burned in the combustor 350, which can heat and reactivate the particulate solids.

[0031] The reactivated particulate solids 104 and the deactivated particulate solids 105 (described below) may enter the combustor 350 through the particulate solids distributor 100. The reactivated particulate solids 104 may be a portion of the particulate solids routed to the combustor via line 356 from the oxygen treatment zone 312 in FIG. 1 , and the deactivated particulate solids 105 may be a portion of the particulate solids routed to the combustor 350 via line 426 from the particulate solids separation section 216. The reactivated particulate solids 104 and the deactivated particulate solids 105 may be routed separately through the particulate solids distributor 100 into the combustor 350. In an embodiment, the reactivated particulate solids 104 and the deactivated particulate solids 105 are not mixed prior to entering the combustor 350. In one or more embodiments, the reactivated particulate solids 104 may enter the combustor 350 downstream of the auxiliary fuel stream relative to the flow direction of the auxiliary fuel stream, and the deactivated particulate solids 105 may enter the combustor upstream of the auxiliary fuel stream relative to the flow direction of the auxiliary fuel stream. In such embodiments, the auxiliary fuel stream may first contact the deactivated particulate solids 105, and then the remaining (unburned) auxiliary fuel may contact the reactivated particulate solids 104. Generally, if any residual supplemental fuel contacts the reactivated particulate solids 104, it will be at a much lower concentration than when it contacts the deactivated particulate solids 105.

[0032] 2, in one or more embodiments, the particulate solids distributor 100 may extend into the combustor 350 through a bottom end of the combustor 350. In one or more embodiments, the particulate solids distributor 100 may deliver reactivated particulate solids 104 into the combustor 350 above the auxiliary fuel distributor 354 and may deliver deactivated particulate solids 105 into the combustor 350 below the auxiliary fuel distributor 354.

[0033] 2 illustrates one contemplated particulate solids distributor. However, other solids distributors may be suitable, and the embodiments described herein should not be construed as limited by the design, shape, size, configuration, etc., of the distributor or distributors that deliver the particulate solids to the combustor 350. For example, the pipe-type distributor disclosed in U.S. Pat. No. 9,360,759 (incorporated herein by reference in its entirety) may be suitable for use with the embodiments described herein.

[0034] As shown in FIG. 2 , in one or more embodiments, the particulate solids distributor 100 may include an inner conduit 200 and an outer conduit 300. The inner conduit 200 may extend from an inner conduit inlet 210 to an inner conduit outlet 220. The inner conduit 200 may be at least partially defined by an inner wall 260. The inner wall 260 may be disposed about a central axis. The outer conduit 300 may extend from an outer conduit inlet 310 to an outer conduit outlet 320. The outer conduit 300 may be at least partially defined by an inner wall 260 and an outer wall 360. The outer wall 360 may be disposed about the central axis, and a cross-section of the outer wall 360 may circumscribe the cross-section of the inner wall 260 in a plane perpendicular to the central axis. The particulate solids distributor 100 may also include a first solids director 240 and a second solids director 340. In some embodiments, as shown in FIG. 2, the first solid director 240 and the second solid director 340 may be a first deflector plate and a second deflector plate.

[0035] The reactivated particulate solids 104 may be routed through the inner conduit inlet 210 to the inner conduit 200, through the inner conduit 200 and out the inner conduit outlet 220 to the first solids director 240, which may direct the reactivated particulate solids 104 into the combustor 350. The deactivated particulate solids 105 may be routed through the outer conduit inlet 310 to the outer conduit 300, through the outer conduit 300 and out the outer conduit outlet 320 to the second solids director 340, which may direct the deactivated particulate solids 105 into the combustor 350.

[0036] 2 , as the auxiliary fuel enters the combustor 350 through the auxiliary fuel distributor 354, the auxiliary fuel contacts an oxygen-containing gas that enters the combustor upstream of the auxiliary fuel flow relative to the flow direction of the auxiliary fuel flow through a pipe 358, causing combustion of the auxiliary fuel. The combustor 350 may include a grid distributor 352 that evenly distributes the oxygen-containing gas across a surface of the grid distributor 352. In one or more embodiments, the grid distributor 352 is not connected to the outer wall 360 of the particulate solids distributor 100. Because the auxiliary fuel distributor 354 is downstream of the pipe 358, the auxiliary fuel entering the combustor 350 contacts the oxygen-containing gas as it enters the combustor 350. Thus, the concentration of the auxiliary fuel within the combustor 350 decreases as the auxiliary fuel moves up through the combustor 350 and away from the auxiliary fuel distributor 354 toward the frustum 353. In one or more embodiments, the concentration of the supplemental fuel in the combustor 350 may be lower in the region where the reactivated particulate solids 104 enter the combustor 350 compared to the concentration of the supplemental fuel in the region where the deactivated particulate solids 105 enter the combustor 350. In some embodiments, 80% or more of the supplemental fuel may be combusted in a region below where the reactivated particulate solids 104 enter the combustor. For example, 85% or more of the supplemental fuel, e.g., 90% or more, 95% or more, or even 99% or more of the supplemental fuel in the supplemental fuel stream, may be combusted before the reactivated particulate solids 104 enter the combustor.

[0037] Without being bound by theory, it is believed that adding the reactivated particulate solids 104 to the combustor 350 downstream of the auxiliary fuel stream relative to the flow direction of the auxiliary fuel stream and adding the deactivated particulate solids 105 to the combustor 350 upstream of the auxiliary fuel stream relative to the flow direction of the auxiliary fuel stream can reduce the amount of a particular particle of the particulate solid that comes into contact with the auxiliary fuel. It is believed that exposing the particulate solids to the auxiliary fuel can reduce the dehydrogenation activity of the particulate solids and reduce the stability of the particulate solids, which can shorten the life of the particulate solids. It is believed that the heat generated by the combustion of the auxiliary fuel can heat particles of the particulate solids closer to the combustion to a temperature high enough to adversely affect the stability of the particulate solids when compared to particles of the particulate solids farther from the combustion of the auxiliary fuel. Therefore, by adding deactivated particulate solids 105 into the combustor at a location upstream of the reactivated particulate solids 104, the deactivated particulate solids 104 are exposed to more auxiliary fuel combustion than the reactivated particulate solids 104 such that the amount of heating of the reactivated particulate solids 104 is reduced, which can improve the stability of the reactivated particulate solids 104 compared to particulate solids exposed to more auxiliary fuel combustion.

[0038] Without being bound by theory, it is also believed that because a portion of the reactivated particulate solids 104 may be returned to the combustor 350, particles of the reactivated particulate solids 104 may circulate through the combustor 350 multiple times before being sent to the reactor section 206. Therefore, if the reactivated particulate solids 104 are returned to the combustor 350 at the same location as the deactivated particulate solids 105 or further upstream, particles that have undergone multiple combustion cycles may be exposed to more supplemental fuel combustion compared to particles utilized in the methods of the present disclosure. By exposing the deactivated particulate solids 105 to a supplemental fuel stream as they come from the reactor section 206, resulting in a higher concentration of supplemental fuel than the reactivated particulate solids 104, the amount of supplemental fuel combustion experienced by individual particles of the particulate solids can be reduced because the highest fuel concentration, and therefore combustion, is experienced by the particles returned to the reactor and then sent to the combustor, rather than by particles repeatedly sent from the oxygen treatment zone 312 to the combustor.

[0039] In one or more embodiments, the deactivated particulate solids 105 passed from the reactor section 206 to the combustor 350 may have a temperature between 580°C and 800°C. For example, the deactivated particulate solid 105 sent from the reactor section to the combustor 350 may be heated to a temperature of 580°C to 775°C, e.g., 580°C to 750°C, 580°C to 725°C, 580°C to 700°C, 580°C to 675°C, 580°C to 650°C, 580°C to 625°C, 580°C to 600°C, 600°C to 800°C, 600°C to 775°C, 600°C to 750°C, 600°C to 725°C, 600°C to 700°C, 600°C to 675°C, 600°C to 650°C, 600°C to 625°C, 625°C to 800°C, 625°C to 775°C, 625°C to 750°C, 625°C to 725°C, 625°C to 700°C, 625°C The temperature may be from 675°C to 650°C, 650°C to 800°C, 650°C to 775°C, 650°C to 750°C, 650°C to 725°C, 650°C to 700°C, 650°C to 675°C, 675°C to 800°C, 675°C to 775°C, 675°C to 750°C, 675°C to 725°C, 675°C to 700°C, 700°C to 800°C, 700°C to 775°C, 700°C to 750°C, 700°C to 725°C, 725°C to 800°C, 725°C to 775°C, 725°C to 750°C, 750°C to 800°C, 750°C to 775°C, 775°C to 800°C, or any combination of these ranges.

[0040] In one or more embodiments, the reactivated particulate solids 104 passed from the oxygen treatment zone 312 to the combustor 350 may have a temperature between 680°C and 900°C. For example, the reactivated particulate solids 104 delivered from the reactor section to the combustor 350 may be heated to a temperature between 680°C and 875°C, e.g., 680°C to 850°C, 680°C to 825°C, 680°C to 800°C, 680°C to 775°C, 680°C to 750°C, 680°C to 725°C, 680°C to 700°C, 700°C to 900°C, 700°C to 875°C, 700°C to 850°C, 700°C to 825°C, 700°C to 800°C, 700°C to 775°C, 700°C to 750°C, 700°C to 725°C, 725°C to 900°C, 725°C to 875°C, 725°C to 850°C, 725°C to 825°C, 725°C to 80 ... The temperature may be from 0°C to 775°C, 725°C to 750°C, 750°C to 900°C, 750°C to 875°C, 750°C to 850°C, 750°C to 825°C, 750°C to 800°C, 750°C to 775°C, 775°C to 900°C, 775°C to 875°C, 775°C to 850°C, 775°C to 825°C, 775°C to 800°C, 800°C to 900°C, 800°C to 875°C, 800°C to 850°C, 800°C to 825°C, 825°C to 900°C, 825°C to 875°C, 825°C to 850°C, 850°C to 900°C, 850°C to 875°C, 875°C to 900°C, or any combination of these ranges.

[0041] The particulate solids can be heated by burning the auxiliary fuel. Because heat transfer from one particle of the particulate solid to another particle of the particulate solid is rapid, it is believed that the heat obtained by burning the auxiliary fuel can be transferred throughout the mass of the particulate solids in the combustor without requiring every particle of the particulate solid to be close to the auxiliary fuel combustion. This may allow only a portion of the particulate solids to be directly exposed to the heat of the auxiliary fuel combustion while simultaneously heating the entire mass of the particulate solids for use in the dehydrogenation reaction. Furthermore, when the two portions of the particulate solids enter the combustor 350, the reactivated particulate solids 104 may be at a higher temperature than the deactivated particulate solids 105, meaning that it may be desirable to heat the deactivated particulate solids 105 more than the reactivated particulate solids 104. Thus, initially exposing the deactivated particulate solids 105 to the auxiliary fuel stream allows more fuel combustion to occur near the deactivated particulate solids 105 than near the reactivated particulate solids 104, thereby heating more of the deactivated particulate solids 105 than the reactivated particulate solids 104.

[0042] Without being bound by theory, it is believed that by introducing the deactivated particulate solids 105 into the combustor 350 upstream of the auxiliary fuel flow, the deactivated particulate solids 105 may have a longer residence time within the combustor 350 than if the deactivated particulate solids 105 were introduced downstream of the auxiliary fuel flow. This extended residence time within the combustor 350 may allow a greater portion of the coke to be removed from the deactivated particulate solids 105 when compared to a shorter residence time within the combustor. It may be desirable to remove as much of the coke that forms on the deactivated particulate solids 105 in the reactor section 206 as possible to reactivate the deactivated particulate solids 105, and a longer residence time within the combustor 350 may remove more coke compared to a shorter residence time within the combustor 350.

[0043] As described herein, in one or more embodiments, the oxygen-containing gas may enter combustor 350 through pipe 358 and lower gas distribution plate 352. In some embodiments, the oxygen in the oxygen-containing gas may react with coke formed on the particulate solids, thereby removing at least a portion of the coke from the particulate solids.

[0044] In a non-limiting example, the reactor system 103 described herein can be utilized to produce olefinic compounds from a hydrocarbon feed stream. As used herein, the term "olefinic compound" refers to a hydrocarbon having one or more carbon-carbon double bonds, separate from the formal double bonds present in aromatic compounds. For example, ethylene and styrene are olefinic compounds, while ethylbenzene is not an olefinic compound because the only double bond present in ethylbenzene is a formal double bond present as part of the aromatic structure. Olefinic compounds can be produced from a wide variety of hydrocarbon feed streams by utilizing different reaction mechanisms. For example, olefinic compounds can be produced by at least dehydrogenation reactions, cracking reactions, dehydration reactions, and methanol-to-olefin reactions. These reaction types can utilize different feed streams and different particulate solids catalysts to produce olefinic compounds. It should be understood that when "catalysts" are referred to herein, they can equally refer to the particulate solids catalysts referred to in connection with the system of FIG. 1.

[0045] According to one or more embodiments, the reaction may be a dehydrogenation reaction. According to such embodiments, the one or more hydrocarbons may be a hydrocarbon feed stream, and the hydrocarbon feed stream may comprise one or more of ethylbenzene, ethane, propane, n-butane, and i-butane. In one or more embodiments, the hydrocarbon feed stream may comprise at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% ethylbenzene. In one or more embodiments, the hydrocarbon feed stream may comprise at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% ethane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% propane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% n-butane. In additional embodiments, the hydrocarbon feed stream may comprise at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% i-butane. In additional embodiments, the hydrocarbon feed stream may comprise a total of at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or even at least 99 wt% ethylbenzene, ethane, propane, n-butane, and i-butane.

[0046] In one or more embodiments, the dehydrogenation reaction may utilize a gallium and / or platinum particulate solid as a catalyst. In such embodiments, the particulate solid may include a gallium and / or platinum catalyst. As described herein, a gallium and / or platinum catalyst includes gallium, platinum, or both. The gallium and / or platinum catalyst may be supported on an alumina or alumina-silica support and may optionally include potassium. Such gallium and / or platinum catalysts are disclosed in U.S. Pat. No. 8,669,406, which is incorporated herein by reference in its entirety. However, it should be understood that other suitable catalysts may be utilized to carry out the dehydrogenation reaction.

[0047] In one or more embodiments, the reaction mechanism may be dehydrogenation followed by combustion (in the same chamber). In such embodiments, the dehydrogenation reaction may produce hydrogen as a by-product, and the oxygen carrier material may contact the hydrogen to promote combustion of the hydrogen to form water. Examples of such reaction mechanisms contemplated as possible reaction mechanisms for the systems and methods described herein are disclosed in International Publication No. WO 2020 / 046978 and U.S. Patent Application Publication No. 2021 / 0292259, the teachings of which are incorporated herein by reference in their entireties.

[0048] In one or more embodiments, the particulate solids catalyst may include an oxygen carrier material and a dehydrogenation catalyst material. In some embodiments, the oxygen carrier material and the dehydrogenation catalyst material may be separate particles of the particulate solid. In some embodiments, the oxygen carrier material and the dehydrogenation catalyst may be contained within the same particle of the particulate solid.

[0049] In some embodiments, the particulate solids catalyst may include a "dual-purpose material" that can act as both a dehydrogenation catalyst and an oxygen carrier material. It should be understood that, at least in the embodiments described herein where an oxygen carrier material and a dehydrogenation catalyst are utilized in the same reactor vessel (such as that of FIG. 1), such dual-purpose materials may be utilized in place of or in combination with the particulate solid oxygen carrier material or the particulate solid dehydrogenation catalyst.

[0050] In one or more embodiments, olefinic compounds may be present in a "product stream," sometimes referred to as an "olefin-containing effluent." Such a stream may exit the reactor system of FIG. 1 and be subsequently processed. In one or more embodiments, the olefinic compounds may include one or more of ethylene, propylene, butylene, or styrene. The term butylene includes any isomer of butylene, such as α-butylene, cis-β-butylene, trans-β-butylene, and isobutylene. In some embodiments, the olefin-containing effluent may include at least 20 wt.%, at least 30 wt.%, at least 40 wt.%, at least 50 wt.%, or even at least 60 wt.% ethylene. In additional embodiments, the olefin-containing effluent may include at least 20 wt.%, at least 30 wt.%, at least 40 wt.%, at least 50 wt.%, or even at least 60 wt.% propylene. In additional embodiments, the olefin-containing effluent may comprise at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% butylene. In additional embodiments, the olefin-containing effluent may comprise at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% styrene. In additional embodiments, the olefin-containing effluent may comprise at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, or even at least 60 wt% of the total of one or more of ethylene, propylene, butylene, and styrene. The olefin-containing effluent may further comprise unreacted components of the feed stream and other reaction products not considered light olefins. The olefin compounds can be separated from the unreacted components in a subsequent separation step.

[0051] In a first aspect of the present disclosure, a method for producing olefin compounds may include contacting a feed stream comprising one or more hydrocarbons with a particulate solids catalyst in a reactor. Within the reactor, the one or more hydrocarbons may be dehydrogenated to form one or more products comprising one or more olefin compounds, and at least a portion of the particulate solids catalyst may be deactivated. The method may also include sending at least a portion of the deactivated particulate solids catalyst to a combustor. Within the combustor, an auxiliary fuel stream may enter the combustor through an auxiliary fuel distributor, and the auxiliary fuel stream may react to heat at least a portion of the deactivated particulate solids catalyst. The method may also include passing at least a portion of the heated deactivated particulate solids catalyst through an oxygen treatment zone to produce a reactivated particulate solids catalyst. The method may also include returning at least a portion of the reactivated particulate solids catalyst to the combustor. Within the combustor, the reactivated particulate solids catalyst may enter the combustor downstream of the auxiliary fuel stream relative to a flow direction of the auxiliary fuel steam, and the deactivated particulate solids catalyst may enter the combustor upstream of the auxiliary fuel stream relative to a flow direction of the auxiliary fuel stream. The method may also include passing at least a portion of the reactivated particulate solids catalyst through a reactor.

[0052] A second aspect of the present disclosure includes any of the preceding aspects or combinations of aspects, wherein the reactivated particulate solids catalyst and the deactivated particulate solids catalyst are delivered to the combustor via a particulate solids distributor that passes the reactivated particulate solids catalyst and the deactivated particulate solids catalyst separately into the combustor.

[0053] A third aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the particulate solids distributor extends into the reactor through the bottom end of the reactor.

[0054] A fourth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the particulate solids distributor routes reactivated particulate solids catalyst into the combustor above the auxiliary fuel distributor and routes deactivated particulate solids catalyst into the combustor below the auxiliary fuel distributor.

[0055] A fifth aspect of the present disclosure includes any of the preceding aspects or combinations of aspects, wherein the combustor operates as a fast fluidized bed, a turbulent bed, or a bubbling bed.

[0056] A sixth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the temperature of the deactivated particulate solids catalyst delivered to the combustor is between 580°C and 800°C.

[0057] A seventh aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the temperature of the reactivated particulate solids catalyst delivered to the combustor is between 680°C and 900°C.

[0058] An eighth embodiment of the present disclosure includes any preceding embodiment or combination of embodiments, wherein the heated deactivated catalyst is exposed to an oxygen-containing gas in an oxygen treatment zone.

[0059] A ninth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the heated deactivated particulate solids catalyst is exposed to an oxygen-containing gas for between 30 seconds and 20 minutes.

[0060] A tenth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the particulate solids catalyst includes one or both of a dehydrogenation catalytic material and an oxygen carrier material.

[0061] An eleventh aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the dehydrogenation catalytic material and the oxygen carrier material are contained within the same particles of the particulate solids catalyst.

[0062] A twelfth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the auxiliary fuel stream includes hydrogen, methane, ethane, propane, natural gas, or a combination thereof.

[0063] A thirteenth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein coke is formed on the deactivated particulate solids catalyst in the reactor and at least a portion of the coke on the deactivated particulate solids catalyst is reacted in the combustor.

[0064] A fourteenth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the particulate solids catalyst is Geldart A or Geldart B particles.

[0065] A fifteenth aspect of the present disclosure includes any preceding aspect or combination of aspects, wherein the one or more hydrocarbons include propane and the one or more olefinic compounds include propylene.

[0066] It will be apparent to those skilled in the art that various modifications and variations can be made to the technology of the present disclosure without departing from the spirit and scope of the technology. Since combinations, subcombinations, and variations of the disclosed embodiments incorporating the spirit and substance of the technology of the present disclosure may occur to those skilled in the art, the technology should be construed as including all within the scope of the appended claims and their equivalents. Furthermore, although some aspects of the present disclosure may be identified herein as preferred or particularly advantageous, it is intended that the present disclosure is not limited to these aspects.

[0067] It should be noted that the various details described in this disclosure should not be construed to imply that these details relate to elements that are essential components of the various embodiments described in this disclosure, even if a particular element is illustrated in each of the drawings accompanying this specification. Unless specifically identified as such, features disclosed and described herein should not be construed as "essential." Contemplated embodiments of the technology include those that include some or all of the features of the appended claims.

[0068] It should be noted that for purposes of describing and defining this disclosure, the term "about" is utilized in this disclosure to express the inherent degree of uncertainty that may result from any quantitative comparison, value, measurement, or other representation. The term "about" is also utilized in this disclosure to express the degree to which a quantitative representation may vary from the basis of description without resulting in a change in the basic functionality of the subject matter in question.

[0069] Where relevant, when a composition is described as "comprising" one or more elements, embodiments of the composition that "consist" or "consist essentially of" those one or more elements are contemplated herein.

[0070] It is understood that the compositional ranges of chemical components in a stream or reactor should, in some embodiments, be understood to contain a mixture of isomers of that component. For example, a compositional range specifying butene may include a mixture of various isomers of butene. It is understood that the examples provide compositional ranges for various streams, and that the total amount of isomers of a particular chemical composition may constitute a range.

[0071] It should be noted that one or more of the following claims utilize the term "where" or "wherein" as a transitional phrase. It should be noted that, for purposes of defining the art, this term is introduced in the claims as an open-ended transitional phrase used to introduce the recitation of a series of features of structure, and should be interpreted in a similar manner to the more commonly used open-ended preamble term "comprising."

[0072] It should be understood that any two quantitative values ​​assigned to a property may constitute a range for that property, and all combinations of ranges formed from all stated quantitative values ​​for a given property are contemplated in the application. When multiple ranges are given for quantitative values, these ranges may be combined to form larger ranges, which are contemplated in the embodiments described herein.

[0073] As understood in the context of the term as used herein, the term "passing" can include passing a substance directly between two portions of the disclosed system, and in some other instances, can mean passing a substance indirectly between two portions of the disclosed system. For example, indirect passing can include passing the specified substance through an intermediate operating unit, valve, sensor, etc.

Claims

1. 1. A process for producing an olefin compound, comprising: contacting a feed stream comprising one or more hydrocarbons with a particulate solids catalyst in a reactor, the one or more hydrocarbons are dehydrogenated to form one or more products comprising one or more olefinic compounds; and at least a portion of the particulate solids catalyst is deactivated; passing at least a portion of the deactivated particulate solids catalyst to a combustor, wherein an auxiliary fuel flow enters the combustor through an auxiliary fuel distributor; and combusting the auxiliary fuel stream to heat at least a portion of the particulate solids catalyst; passing at least a portion of the heated deactivated particulate solids catalyst through an oxygen treatment zone to produce a reactivated particulate solids catalyst; returning at least a portion of the reactivated particulate solids catalyst to the combustor, the reactivated particulate solids catalyst entering the combustor downstream of the auxiliary fuel stream relative to a flow direction of the auxiliary fuel stream and the deactivated particulate solids catalyst entering the combustor upstream of the auxiliary fuel stream relative to a flow direction of the auxiliary fuel stream; and passing at least a portion of said reactivated particulate solids catalyst through said reactor.

2. 10. The method of claim 1, wherein the reactivated particulate solids catalyst and the deactivated particulate solids catalyst are delivered to the combustor through a particulate solids distributor that passes the reactivated particulate solids catalyst and the deactivated particulate solids catalyst separately into the combustor.

3. The method of claim 2 , wherein the particulate solids distributor extends into the combustor through a bottom end thereof.

4. 4. The method of claim 3, wherein the particulate solids distributor directs the reactivated particulate solids catalyst into the combustor above the auxiliary fuel distributor and directs the deactivated particulate solids catalyst into the combustor below the auxiliary fuel distributor.

5. The method of any one of claims 1 to 4, wherein the combustor operates as a fast fluidized bed, a turbulent bed, or a bubbling bed.

6. A method according to any one of claims 1 to 5, wherein the temperature of the deactivated particulate solids catalyst fed to the combustor is from 580°C to 800°C.

7. A method according to any one of claims 1 to 6, wherein the temperature of the reactivated particulate solids catalyst fed to the combustor is from 680°C to 900°C.

8. 8. The process of any one of claims 1 to 7, wherein in the oxygen treatment zone the heated deactivated particulate solids catalyst is exposed to an oxygen-containing gas.

9. 9. The method of claim 8, wherein the heated deactivated particulate solids catalyst is exposed to the oxygen-containing gas for a period of from 30 seconds to 20 minutes.

10. 10. The method of any one of claims 1 to 9, wherein the particulate solids catalyst comprises one or both of a dehydrogenation catalytic material and an oxygen carrier material.

11. 11. The method of claim 10, wherein the dehydrogenation catalytic material and the oxygen carrier material are contained within the same particles of the particulate solids catalyst.

12. The method of any one of claims 1 to 11, wherein the auxiliary fuel stream comprises hydrogen, methane, ethane, propane, natural gas, or a combination thereof.

13. 13. The method of any one of claims 1 to 12, wherein coke is formed on the deactivated particulate solids catalyst in the reactor and at least a portion of the coke on the deactivated particulate solids catalyst reacts in the combustor.

14. A process according to any one of claims 1 to 13, wherein the particulate solids catalyst is Geldart A or Geldart B particles.

15. 15. The method of any one of claims 1 to 14, wherein the one or more hydrocarbons comprise propane and the one or more olefinic compounds comprise propylene.

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